Environmentally friendly container with bioplastic shell and glass lining

ABSTRACT

An environmentally friendly container with bioplastic shell and glass lining includes a shell defining a hollow body of the container; a wall of the shell that includes a bioplastic resin; and a lining that includes a liquid glass and coats a surface of the wall. Embodiments may include an opening at an end of the shell; a cap that includes the bioplastic resin of the shell; and a cap lining on an inner surface of the cap, the cap lining forming a closure with the lining of the wall so that the container provides a sealed cavity; wherein the lining is on an inner surface of the wall of the shell, thereby fully lining an interior cavity of the container with glass; and the bioplastic resin includes PLA, PLLA, PDLA, PHA, PCL, or PBT.

BACKGROUND OF THE INVENTION

The present invention relates to containers and specifically to an environmentally friendly container with a bioplastic shell and a glass lining.

There is a desire to make products that are environmentally friendly, from plant materials that are compostable, which thus can lead to zero waste, thereby reducing waste. This can be achieved by using material that are compostable and are from a plant source, namely Bioplastic resins. We need to move away from recycling and take a zero waste approach.

Traditionally, many drinks and beverages such as soft drinks, water, juices, wine, beer, and milk have been supplied in glass, aluminum or plastic bottles. However, these glass, plastic and aluminum materials require much more energy than bioplastic materials to be made into bottles. Bioplastics and ultra-thin liquid or flexible glass are of much lighter weight compared to glass and aluminum thereby decreasing the amount of energy required to produce the bottles.

Existing containers may be made with a shell made from wood or paper pulp, which offers very poor water vapor and gas barrier. Such a shell is opaque and not translucent like bioplastics. Existing inner pouches are made from plastic which is from petroleum with higher carbon footprint and non-renewable resource.

Existing containers related to a flexible food packages may include a laminate body that includes an inner and outer layer of which one is made from green PE, polyethylene, green polyethylene terephthalate, or green PET and second layer is PLA. Existing methods may teach how to make a packing device to hold liquid crystal glass. Existing containers may use liquid crystal glass to make shutters or eyeglasses. Liquid glass is food safe, environmentally friendly (winner of the Green Apple Award) and it can be applied to almost any surface within seconds.

Bioplastics are from a renewable resource, have a smaller carbon foot print than other plastics and use less energy, which are upstream advantages. The downstream advantages of bioplastics are they may be compostable which may lead to zero waste. Ultra-thin liquid or flexible glass layers may also help reduce the carbon footprint of the glass, which is also from a renewable resource, namely silica.

Plastic, paper and pulp based bottles are lightweight, can be formed easily at low cost, and are widely used in various industries as containers. Bioplastic resins are derived from plants like corn and sugarcane. These bioplastics resins namely are polylactic acid (PLA) from corn, cellulose based PHA, polycaprolate (PCL), polybutyleneadipatetetephathalate (PBT), polyhydroxyalkanoate (PHA). These bioresins can be blow molded, injection molded or extruded into any desired shaped bottle, and the bottle acts as an outer shell.

Bioplastics may be from a renewable resource and have a small carbon foot print, which is an upstream advantage. Bioplastics may be compostable, which is a downstream advantage. Bioplastics are “biodegradable” because they break down under the action of living organisms.

Glass is generally not “biodegradable”, but it is “degradable” because it eventually breaks down and decomposes by physical forces acting on its structure. Glass is made from sand and minerals which have already been around for millions of years. The utilization of glass therefore provides an upstream advantage because its production and use does not directly require introduction of carbon or other undesirable environmental pollutants into the environment. In other words, glass may reduce the “carbon footprint” of a container.

It would be desirable to have a container that has strong permeability properties, but with little or no carbon footprint.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a container includes a shell defining a hollow body of the container; a wall of the shell that includes a bioplastic resin; and a lining that includes liquid glass and coats a surface of the wall.

In another aspect of the present invention, a container includes a shell defining a hollow body of the container; a wall of the shell that includes a bioplastic resin; a lining that includes thin, flexible coating of liquid glass and that coats an inner surface of the wall; an opening at an end of the shell; a cap that includes the bioplastic resin of the shell; a cap lining on an inner surface of the cap, the cap lining forming a closure with the lining of the wall so that the container provides a sealed cavity sealed in glass; wherein the lining is on an inner surface of the wall of the shell, thereby fully lining an interior cavity of the container with glass; and the bioplastic resin includes PLA, PLLA, PDLA, PHA, PCL, or PBT.

In yet another aspect of the present invention, a method for making a container includes forming a shell that defines a hollow body of the container, the shell having a wall that includes a bioplastic resin; and coating the wall with a lining that includes liquid glass.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an embodiment of the present invention;

FIG. 1A depicts a close-up view of a casing of the embodiment of FIG. 1;

FIG. 2 depicts an alternate embodiment of the present invention; and

FIG. 2A depicts a close-up view of a casing of the embodiment of FIG. 2.

DETAILED DESCRIPTION

The preferred embodiment and other embodiments, which can be used in industry and include the best mode now known of carrying out the invention, are hereby described in detail with reference to the drawings. Further embodiments, features and advantages will become apparent from the ensuing description, or may be learned without undue experimentation. The figures are not necessarily drawn to scale, except where otherwise indicated. The following description of embodiments, even if phrased in terms of “the invention” or what the embodiment “is,” is not to be taken in a limiting sense, but describes the manner and process of making and using the invention. The coverage of this patent will be described in the claims. The order in which steps are listed in the claims does not necessarily indicate that the steps must be performed in that order.

The present invention relates to a bioplastic container made with two layers of material. Embodiments may include a package and a method of forming a package. The invention may relate to a package that is easily disposable, and an outer shell that is compostable.

The present invention relates to a package and to a method of forming a package. The invention particularly relates to a package that is easily disposable, and an outer shell that is compostable.

There may be environmental advantages in using bioplastics and ultra-thin liquid glass. Bioplastics are derived from plants, and thus have smaller carbon foot print and are from a renewable resource. An outer bioresin shell may be biodegradable and compostable, and lead to zero waste. An inner shell that made from ultra-thin liquid flexible glass that is only a fraction of the thickness of glass may reduce the glass based carbon footprint of a container

In an embodiment, ultra-thin liquid or flexible glass layers may help reduce the carbon footprint of the glass, which is from a renewable resource, namely silica. Embodiments of the present invention may reduce the carbon foot print, reduce waste or try to achieve zero waste, and go beyond recycling to providing composting by using bioplastics.

In accordance with a general aspect of the present invention, there is provided a container comprising a hollow shell defining the container body and including an opening, and an inner lining of ultra-thin liquid flexible glass made by spraying or by blow molded on the inner surface of the outer shell. The thin layer of glass may extend through and over the opening of the shell, so that layer of glass provides a pouch that is the only part of the container that comes in direct contact with the contents of the container. The container may be secured by a cap on the outside of the shell. The cap may be made from a bioresin or bio based rubber material. The inner lining may be made from ultra-thin liquid glass and may hold the contents of the container.

Embodiments of a cap may include the same ultra-thin liquid glass lining as the shell so that the glass lining of the shell and the cap provide a container that is completely lined with glass or a biobased rubber. The cap may include the same bioplastic resin as the shell, and may form a closure with the opening of the container. A cap lining on an inner surface of the cap may include glass, similar to the glass lining of the shell. The glass lining may coat all of the inner wall surface of the shell and may extend to the top of the shell or possibly onto the outer wall surface, so that when the cap is attached to the shell, the cap lining engages with the glass lining of the shell to provide a container with an interior cavity that is completely lined with glass.

Embodiments of container may have a wall or walls and a cap that meet moisture resistant or waterproof or gas permeation requirements. The container may hold liquids or solids that are sensitive to moisture and water vapor permeation, or gas permeation for gasses such as oxygen and carbon dioxide. The outer shell may be made from a bioresin, and the inner lining may be made from ultra-thin liquid or flexible glass, which may be co blow molded or coextruded as a two layered bottle or sprayed as an inner coat. The coat may be applied on the inside and around the outside or outer, exposed portions of the opening, where the cap attaches. The container and liner may be secured by a cap that screws on to or otherwise attaches to the outside of the shell.

In an embodiment, the contents of the container may be introduced and dispensed through the opening or mouth of the container without coming into contact with any part of the hollow shell, including the inside of the mouth. The hollow shell may be made from bioresins, namely PLA (polylactic acid), polycaprolate (PCL), polybutyleneadipatetetephathalate (PBT), or polyhydroxyalkanoate (PHA). The cap may also be made from the same bioresin or bio based rubber material. In embodiments that improve flexibility to rigid bioresins, a plastizer such as acetyl tributyl citrate (ATBC) or poly butylene adipate terephthalate (PBAT) may be added to create a flexible container.

Embodiments of the present invention may relate to containers that are specifically made from bioplastic resins for packaging both solids and fluids. The inner shell may be made from ultra-thin liquid flexible glass. The thickness of the ultra-thin liquid flexible glass, when applied as the inner lining, may range from 100 nanometers (0.0001 mm) to 0.5 mm.

In an embodiment, liquid glass may be made by extracting molecules of Silicon Dioxide (SiO2) from quartz and sand. Silicon dioxide is the primary constituent of glass. These molecules may then be added to a propellant, such as water or ethanol, to form a liquid glass spray or wipe-on liquid. The flexible and breathable liquid glass coating surface may be approximately 100 nanometers thick, or 500 times thinner than a human hair, so it may be completely or partially visually undetectable to a user.

Embodiments of surfaces that are coated with liquid glass may be made easier to clean and may give anti-microbial protection. Embodiments may include a bioplastic resin combined with glass, which may be converted into a patty that can be blow molded or extruded.

Embodiments may include liquid glass made from silicon dioxide, which is a natural element from silica or sand (“glass”). Embodiments may provide a container that is made from environmentally friendly material compared to plastics, and may maintain the barrier properties of plastics, which paper and pulp cannot offer. Embodiments may avoid use of any material from petroleum or non-renewable resources.

Embodiments of the present invention may include a container having an outer shell defining a body with an opening. The shell may have an inner lining that consists of an ultra-thin liquid or flexible glass. The lining material may be blow molded through the opening of a pre-prepared outer shell, or an inner shell may be formed and then encased by an outer shell. The open end of the inner lining may extend up to and over an opening or dispensing aperture in the outer shell. The opening may be secured over the outside of the shell by a cap. The inner lining may made from liquid glass material that meets high water vapor and gas barrier properties, which may be more effective than material used in the outer shell. The outer shell may be made from a plant material that is a biodegradable resin, such as polylactic acid (PLA), PLA derived polymers such as Poly L lactide (PLLA) and poly D lactide (PDLA), cellulose based polyhydroxyalkanoate (PHA), polycaprolate (PCL), or polybutyleneadipatetetephathalate (PBT). Other resins that offer higher heat distortion properties may also be used. In an embodiment, the inner shell may be separable from the main body of the container to allow for separate disposal. The container may be sealed by providing a cap that forms a releasable closure, made from the same bio resin or bio based rubber material.

FIG. 1 depicts an embodiment of a container 10 with a generally cylindrical main body, an upper portion having a neck portion 12, an opening 14, a shoulder 16, and a cap 20. Container 10 may have a composite casing 18 with a bioplastic wall 19. Cap 20 may be secured to opening 14, so that container 10 will have a releasably sealed interior cavity that hold fluids 22 and air or gas 24 to meet FDA requirements for storage of food or medicine. The composite casing 18 or walls 19 of container 10 may include a bioresin including glass made by a blow molding, injection molding, or extrusion process.

FIG. 1A depicts an embodiment of a section of composite casing 18 with a bioplastic wall 17 or shell made of bioresin that includes or consists of glass. The bioresin may include a biodegradable plant material that is a biodegradable resin combined with silicon dioxide. The bioresin may be provided in a form such as a patty, and then a container or other object may be made by a blow molding, injection molding, or extrusion process with the patty.

FIG. 2 depicts a front view of an embodiment of a container 30 for storing liquids 32 or fluids and air or gas 34, with a layered casing 48 that has a glass inner lining 52 and a biodegradable outer shell 54. Container 30 may have a generally cylindrical main body, an upper portion having a neck portion 42, an opening 44, a shoulder 46, and a cap 50. Container 30 may have a layered casing 48 with a glass inner lining 52 and a biodegradable outer shell 54. Cap 50 may be secured to opening 44, so that container 30 will hold fluids 32 and air or gas 34 to meet FDA requirements for storage of food or medicine. Embodiments of a glass inner lining or layered casing 48 may include an ultra-thin liquid flexible glass coating or glass inner lining 52 made by spraying or by blow molding a liquid glass material onto the inner surface of the outer shell 54.

Container 30 may have a base 62 may include four to seven angularly spaced downwardly projecting feet 64, generally parallel-sided straps 66 between the feet 64, and a central area 68 defining a smooth domed generally pressure-vessel-shaped surface 70. This surface 70 may be roughly hemispherical to help withhold high pressures and avoid creep, but the central area 68 may be flat.

FIG. 2A depicts an embodiment of a section of layered casing 48 or bioplastic wall with a glass inner lining 52 and a biodegradable outer shell 54. The bioplastic wall or shell is made of bioresin that includes one or more layers of glass. The bioresin may include a biodegradable plant material that is a biodegradable resin combined with silicon dioxide. The bioresin may be provided in a form such as a patty, and then a container or other object may be made by a blow molding, injection molding, or extrusion process with the patty.

In an embodiment, the bottom of the bottle may have somewhat greater thickness than the sidewall of the body of the bottle, to help have greater strength and resistance to gas permeation. Other embodiments have different shapes of the bottom may change, to accommodate the stress of the liquid and gas pressure in the bottle. If the liquid contents under elevated pressure do not distort the flat bottom of the bottle or make it fracture, the bottle may remain steady and not topple.

An embodiment may include a container comprising a hollow outer shell, which forms a container body of the container, with an opening through which is a liquid glass coating is sprayed or liquid glass is blow molded or coextruded to form an inner lining made from ultra-thin liquid or flexible glass. The liner has an open end, the liner goes over the opening of the hollow shell and is secured by a cap, the shell and cap are made from a bioresin or a bio based rubber material.

An embodiment may include a container in which the inner lining is secured with respect to the outside of the hollow shell by a cap. An embodiment may include a container where the outer shell is made from bio plastic namely PLA, PLLA, PDLA, PHA, PBT, PCL. An embodiment of a container may include of a hollow outer shell, which forms a container body of the container, with an opening that encases an inner shell made from ultra-thin liquid or flexible glass and is secured by a cap, the shell and cap are made from bioresin or bio based rubber material. An embodiment may include a container made with a co-two layered blow molding and extrusion of bioresin and ultra-thin liquid or flexible glass. Embodiments may include a container made from PLA, PLLA, PDLA and PHA, PBT, or PCL, which may be spray coated with liquid glass to form an inner lining. 

I claim:
 1. A container comprising: a shell defining a hollow body of the container; a wall of the shell that includes a bioplastic resin; and a lining that includes liquid glass and coats a surface of the wall.
 2. The container of claim 1, wherein the lining is on an inner surface of the wall of the shell, thereby fully lining an interior cavity of the container with liquid glass.
 3. The container of claim 1, further comprising: an opening at an end of the shell; a cap that includes the bioplastic resin of the shell, the cap forming a closure with the opening that seals the container.
 4. The container of claim 1, further comprising: an opening at an end of the shell; a cap that includes the bioplastic resin; and a cap lining on an inner surface of the cap, the cap lining forming a closure with the lining of the wall so that the container provides a sealed cavity.
 5. The container of claim 4, wherein the cap lining includes liquid glass.
 6. The container of claim 4, wherein the cap lining includes biobased rubber.
 7. The container of claim 1, wherein the bioplastic resin and glass are pre-selected to provide a container that meets a specified gas permeation level, where the gas includes oxygen and carbon dioxide.
 8. The container of claim 1, wherein the bioplastic resin includes polylactic acid (PLA), Poly L lactide (PLLA), poly D lactide (PDLA), polyhydroxyalkanoate (PHA), polycaprolate (PCL), or polybutyleneadipatetetephathalate (PBT).
 9. The container of claim 1, wherein the lining and the bioplastic resin are coextruded to form the wall.
 10. The container of claim 1, wherein the lining is a thin, flexible coating of glass on an inner surface of the wall.
 11. The container of claim 1, wherein the lining has a thickness of from 100 nanometers to 0.5 mm.
 12. The container of claim 1, wherein the glass is a spray coating on an inner surface of the shell.
 13. The container of claim 1, wherein the shell consists entirely of a bioplastic resin and the lining consists entirely of a thin layer of liquid glass.
 14. A container comprising: a shell defining a hollow body of the container; a wall of the shell that includes a bioplastic resin; a lining that includes thin, flexible coating of liquid glass and that coats an inner surface of the wall; an opening at an end of the shell; a cap that includes the bioplastic resin of the shell; a cap lining on an inner surface of the cap, the cap lining forming a closure with the lining of the wall so that the container provides a sealed cavity; wherein the lining is on an inner surface of the wall of the shell, thereby fully lining an interior cavity of the container with glass; and the bioplastic resin includes polylactic acid (PLA), Poly L lactide (PLLA), poly D lactide (PDLA), polyhydroxyalkanoate (PHA), polycaprolate (PCL), or polybutyleneadipatetetephathalate (PBT).
 15. A method for making a container, comprising: forming a shell that defines a hollow body of the container, the shell having a wall that includes a bioplastic resin; and coating the wall with a lining that includes liquid glass.
 16. The method of claim 15, wherein the lining is on an inner surface of the wall of the shell, thereby fully lining an interior cavity of the container with liquid glass.
 17. The method of claim 15, further comprising: forming the shell to have an opening at an end of the shell; providing a cap that includes the bioplastic resin of the shell, the cap forming a closure with the opening that seals the container.
 18. The method of claim 15, further comprising: forming an opening at an end of the shell; providing a cap that includes the bioplastic resin; and lining the inner surface of the cap with a cap lining that forms a closure with the lining of the wall so that the container provides a cavity sealed in glass.
 19. The method of claim 15, further comprising: blow-molding a bioplastic resin to provide the shell; and spray coating the shell with a layer of glass.
 20. The method of claim 15, further comprising: coextruding a bioplastic resin and a glass to provide two layers that form the wall of the shell. 